Control valve means



Dec. 4, 1962 s. A. LUNDEEN CONTROL VALVE MEANS a m m NN S EU q W/.. m YS E 3 M m T W Y B 5 5 m w 6 w/w 1 8 n m 6 9 7 l M I 6 F n w d m .m .1 5F m ATTORNEY! Dec. 4, 1962 s. A. LUNDEEN 3,065,801

CONTROL VALVE MEANS Filed Feb. 19. 1958 s Sheets-Sheet 5 f w /Z34- HARDWATER SOFT WATER INLET OUTLET -1v--- 195 If 213 238 22a f 1 21a 225 2/43 INVENTOR.

STA NL E Y/I. UNDEEN wad,

hired This application relates to a multi-functional control valvemeans. More particularly, this invention relates to a versatilemulti-functional, multi-port control valve means for automatic watersoftening systems.

The principal object of this invention is to provide a compact versatilecontrol valve means for automatic Water softening systems adapted topermit a variety of sequences of operating cycles in the regeneration ofthe mineral water softening bed of the water softening system.

A further object of this invention is to provide a compact versatilefluid pressure actuated diaphragm valve 1 cans for controlling theoperation of an automatic water softening system.

Other objects of the invention will become apparent as the descriptionproceeds.

To the accomplishment of the foregoing and related ends, this inventionthen comprises the features hereinafter fully described and particularlypointed out in the claims, the following description setting forth indetail certain illustrative embodiments of the invention, these beingindicative, however, of but a few of the various Ways in which theprinciples of the invention may be employed.

The invention is illustrated by the drawings in which the same numeralsrefer to corresponding parts and in which:

FIGURE 1 is a top plan view of one embodiment of the control valve meansof this invention, shown partly broken away to reveal the interior ofthe valve body;

FIGURE 2 is a vertical section through the valve means taken on the lineof FIGURE 1 and in the direction of the arrows;

FlGURE 3 is an enlarged section taken on the line 3--3 of FlGURE 2 andin the direction of the arrows;

FIGURE 4 is a vertical section taken on the line 4-4 of FiGURE l and inthe direction of the arrows;

FIGURE 5 is a partial horizontal section taken on the line 5--5 ofFIGURE '2 and in the direction of the arrows;

FIGURE 6 is a partial vertical section taken on the line 6-6 of FIGURE 2and in the direction of the arrows; and

FlGURE 7 is a schematic representation of the elements of the controlvalve means according to this invention shown in conjunction with otherelements of an automatic water softening system operatively connected tocontrol a three phase regeneration cycle.

The control valve means indicated generally at 151, includes a baseflange 152 adapted to be secured to the open end of the mineral tank ofa water softening system. The bottom surface of the flange 152 isprovided with a gasket or an annular groove 153 to receive a resilientO- ring to form a seal to prevent leakage between the top of the watersoftening tank and the bottom of the valve body. The liange 152 is alsoprovided with openings 154 adapted to receive bolts or equivalentfastening means for securing the control valve means to the mineraltank. The bottom of the base flange of the control valve means isprovided with a central annular projecting collar 155 adapted to receivethe upper end of a pipe or tube connecting the control valve means withthe bottom of the mineral tank and function as a soft water inlet, asexplained in greater detail hereinafter. The inner surface of collar 155is provided with an annular groove 156 adapted to receive a resilientO-ring to frictionally en- Iifilihfifll Patented Dec. 1962 gage the endof the tube inserted in the collar and to prevent leakage around thattube.

The control valve means is provided with a hard Water inlet port 157adapted to be connected by means of conventional plumbing connectionsand fittings to any domestic or commercial water distribution systemsupplying hard water. The control valve means is also provided with asoft water outlet port 158 adapted to be connected by means ofconventional plumbing fittings to any commercial or domestic waterdistribution system for supplying soft water to the taps and faucets ofthat system. Hard water inlet 157 communicates directly with a chamber559 integrally formed in the body of the valve means. A further externalport 16% communicates directly with chamber 159 in the control valvebody and is adapted to be fitted with a connection extending to a flowline to a series of solenoid controlled valves and to maintain watermain pressure on the diaphragm of a metering valve, as explained ingreater detail hereinafter.

Chamber 159 also communicates directly with the lower pressure chamber161 of a first pressure controlled diaphragm valve, indicated generallyat 152. The lower pressure chamber 161 of the first diaphragm valve 162is formed integrally with the control valve body. A cap 163 I providedwith a shallow bowl-shaped depression 164 which acts as an upperpressure chamber in the completed valve is adapted to be secured overthe lower pressure chamber ll by means of screws or bolts, or equivalentfastening means. A resilient diaphragm 165 is fitted between opposedfaces of the cap 163 and the portion of the control valve bodysurrounding the lower pressure chamber 161.

The lower pressure chamber 161 is provided with a central annular valveseat fitting 1&6 whose central channel 167 communicates directly with ahard water outlet port 168 leading to the top of the mineral watersoftening tank. It will be seen that when the water pressure in thelower pressure chamber M1 exceeds the total pressure in the upperpressure chamber 164 that the diaphragm valve 162 is open and permitsflow of hard water from the hard water inlet 157, through the chamber159, through the lower pressure chamber 161 and thence through channel167 to the outlet port 168 to the water softening bed. Means areprovided in the cap 163 for interrupting this normal flow duringregeneration of the mineral water softening bed by applying increasedpressure on the upper side of the resilient diaphragm 165 in the upperpressure chamber 164.

The valve cap 163 includes a tubular pressure chamber extension 169 ofsomewhat lesser diameter than the upper pressure chamber 164. The end ofthe pressure chamber extension 169 opposite to the diaphragm 165 isprovided with an outlet port 170 of substantially reduced diameter. Acoil spring 171 seats in the pressure chamber extension 169 to normallyurge the resilient diaphragm 165 against the valve seat 166 to close thediaphragm valve 162. Water pressure is applied to the upper pressurechamber 164 through port 170 through a two-Way check valve including atransverse channel 172 in the outer end of the cap 163 fitted with aball valving element 173 or other similar functioning valving element,such as a sliding cylindrical plug.

The ball valving element 173 is of a size to fit with a loose rolling tin the channel 1'72 and is held in place by a pair of fittings 174 arid175, each adapted to be connected to a separate pressure source. Whenwater pressure is applied through the fitting 174, the ball 173 isforced against the opening in the inner end of fitting 175 preventingfiow out through that fitting while at the same time permittingapplication of the Water pressure through the port 170 to the chambers15) and 164 and against the resilient diaphragm 165. In the same manner,when pres- 3 sure is applied through the fitting 175, the ball is forcedagainst the opening in the inner end of fitting 174 to prevent outwardtlow of fluid through that fitting while at the same time permitting theapplication of pressure against the diaphragm 165.

The entry chamber 159 from the hard water inlet 157 also communicatesdirectly with the lower pressure chamber 176 of a second pressurecontrolled diaphragm valve indicated generally at 177. The lowerpressure chamber 176 is in the form of a shallow depression formedintegrally with the control valve body. A cap 178 is adapted to befitted over the lower pressure chamber 175 and secured by means ofscrews or bolts or equivalent fastening elements. The cap 178 isprovided with a shallow bowlshaped depression 179 which serves as anupper pressure chamber in the assembled valve. A resilient diaphragm 189is fitted between the opposed faces of the control valve bodysurrounding the lower pressure chamber 17 6 and cap 178 so that when thecap is secured in place on the control valve body, a fluid tight seal isformed.

An annular valve seat 181 is fitted into a central opening in the bottomwall of the lower pressure chamber 176 of the second diaphragm valve177. Central channel 182 through the valve seat element 181 communicatesdirectly with an interior chamber 183 in the control valve body. Aone-way check valve element 184 seats in an opening in the bottom wallof chamber 183 which communicates with the chamber 186 contained withinthe annular sleeve 155 in the bottom of the control valve body. Thecheck valve element 184 prevents flow from chamber 183 to chamber 186when the pressure in chamber 183 is greater than that in chamber 186,but permits flow in the opposite direction when the pressure in chamber186 is greater than that in chamber 183.

Although a simple ball check valve element Will function in thisinstance, a preferred form of check valve construction is illustratedand comprises a fiat disc 187 having a peripheral annular groove fittedwith a resilient O-ring 188 and provided with a depending pilot stem189. The pilot stem 189 is formed from two identical slotted sheet metalpieces fitted together at right angles to one another in theirrespective slots and soldered or similarly secured to the bottom surfaceof the disc 187.

Soft water outlet 158 communicates directly with chamber 183 in theinterior of the control valve body. So long as the pressure in upperpressure chamber 179 is greater than that in the lower pressure chamber176, as is true during the normal water softening cycle of a watersoftening system, the resilient diaphragm 189 is held in place againstthe valve seat 181 and the second diaphragm valve 177 is closed. Thus,during the normal water softening cycle, soft water from the mineralwater softening bed enters chamber 186 from the tube held in the collar155 and lifts the check valve element 184 so that soft water may flowinto the chamber 183 and out through the soft Water outlet 158.

On the other hand, when the pressure is greater in lower pressurechamber 176 than in the upper pressure chamber 179, as is true duringthe regeneration cycle of the water softening system, then the resilientdiaphragm is forced away from the valve seat 181 and the seconddiaphragm valve 177 is opened. Thus, during regeneration, hard waterfrom the hard water inlet 157 is bypassed through chamber 159, intolower pressure chamber 176, through channel 182 to chamber 183 and softwater outlet 158. It will be seen that if any of the soft water tapsconnected to the water softening system are opened during the periodthat regeneration is taking place, fresh (but hard) water will be drawnfrom those taps. However, since regeneration is scheduled to take placeduring periods of least water consumption, in the normal course thereshould be no occasion to draw water during the period that regenerationis taking place. The hard water by-pass insures that the waterdistribution system of which the softener is a part, remains operativeat all times. Cap 1'78 of diaphragm valve 177 is provided with a tubularextension of upper pressure chamber 179 in which a coil spring 191 isseated. Coil spring 191 normally urges the resilient diaphragm 180against the valve seat 181 to maintain the diaphragm valve 177 in closedposition. Fluid pressure is introduced into the upper pressure chamber179 by means of a duct 192 in the rim of cap 178, through an openingadjacent to the edge of diaphragm 180, which, in turn, communicates witha duct 193 through the control valve body and with a channel 194, whichfunctions as a second port connecting the control valve means and thetop of the Water softening tank upon which it is used. In this manner,the full pressure of the top of the water softening tank (which issubstantially the pressure of the hard water main) is maintained againstthe top of the resilient diaphragm 189 during the water softening cycle.

The opposite end of channel 194 communicates directly with an interiorchamber 195 in the control valve body. The upper portion of channel 195is tapped to receive the threaded body of a first diaphragm drain valve,indicated generally at 196. The diaphragm drain valve 196 includes athreaded casing 197 provided with a shallow bowlshaped interiordepression 198 which serves as a lower pressure chamber for thecompleted valve. The valve casing 197 is provided with a central annularchannel 199 which serves as an extension of the pressure chamber 198 anda somewhat narrower outlet channel or port 209 communicating with thechamber 195 in the control valve body.

The lower end of the outlet port 291 is provided with an annular grooveinto which there is fitted a resilient O- ring 201. A pair of ports 292and 293 in the Wall of the drain valve casing communicate with thepressure chamber 198 and pressure chamber extension 199. The diaphragmdrain valve 196 includes a cap 204- provided With an interior shallowbowl-shaped depression 205 which functions as an upper pressure chamberin the completed valve. A pair of ports 206 and 297 communicate with thepressure chamber 295. A resilient diaphragm 2138 is fitted between theopposed faces of the casing 197 and the cap 294. Depending from thecenter of diaphragm 298 is a valving member including an elongated stem289 at the end of which is a frusto-conical valving element adapted toseat within the resilient O-ring 201.

An open 3-footed spider or bridging member 211 rests in the bottom ofthe pressure chamber extension 199 and provides a seat for a coil spring212 which normally urges the resilient diaphragm 298 upwardly so as tomaintain the conical valving element 210 seated against the O-ring 201so that the drain valve 196 is normally maintained closed. The functionof the spider 211 is to permit free flow of water through the valve whenthe valve is open. Without the use of the spider, it occasionallyhappens that the coils of the coil spring 212 may be so tightlycompressed as to inhibit the flow of water through the coil spring. Thespider 211 is provided with a central annular upwardly extending flangewhich functions to center the coil spring 212 around the valve stem 299.

It will be seen that because of the pressure of coil spring 212 thediaphragm drain valve 196 will normally be closed. However, uponintroduction of pressure to the upper pressure chamber 205, sufiicientto overcome the pressure exerted by the coil spring, the spring Will becom-- pressed and the plunger moved so that the valve will be opened andflow from chamber 195 into channel 200 and pressure chamber 198 and 199and out through port 202 or 203 will be permitted.

A one-way check valve 213 is disposed in an opening in the bottom wallof chamber 195 connecting with an inlet port 214 to the control valvebody. The construction of check valve 213 is substantially the same asthat previously described for check valve 184. Check valve 213 iseffective to prevent flow of water from chamber 195 to port 214 but uponapplication of greater pressure upon aoeaeor port 214 than upon chamber195 the check valve 213 will lift and permit flow of water from theinlet 214.

A channel 215 communicates between chamber 186 in the bottom of thecontrol valve body and another interior chamber 216. The top of chamber216 is tapped to receive a threaded second diaphragm drain valve,indicated generally at 217. The construction of the second drain valve217 is in all respects similar to that described in detail for drainvalve 196 and these details will not be repeated. A check valve 21% isprovided in the opening in the bottom Wall of chamber 216 connectingwith a further inlet port 219. The construction of check Valve 21% issubstantially the same as that already described for check valve 184.Check valve 213 functions to prevent the flow of water from chamber 216to port 21) while permitting flow in the opposite direction from port219 to chamber 216.

A port 22% communicates with chamber 183 adjacent the soft water outlet.Through port 228 the control valve is connected to the inlet of ametering valve according to my co-pending application, Serial No.676,777, filed August 7, 1957, to meter soft water into a brinegenerating device for the generation of a brine solution proportional tothe volume of soft water drawn through the soft water outlet of thecontrol valve means.

The utility and functioning of the control valve means of this inventionwith reference to one automatic water softening system is illustratedschematically in FIGURE 7. The water softening system illustrated inFIGURE 7 is so organized as to provide a three-phase regeneration cycle.In the first phase, the regeneration cycle is initiated and brine forrevitalization of the mineral water softening bed is drawn from a brinegenerating vessel, introduced to the bottom of the mineral bed andforced upwardly through the bed. In the second phase, the direction offlow is reversed and the brine which has collected in the freeboard ofthe water softening tank is forced downwardly through the mineral 'bedand followed by a wash with fresh water in the same direction. Duringthe third phase of regeneration, the mineral bed is washed with freshwater in an upflow operation and the regeneration cycle is terminated.

It is to be understood that this is but one arrangement in which thecontrol valve means of this invention may be utilized. Depending uponthe organization of the elements comprising the water softening systems,the phases of the regeneration cycle and their sequence of operation maybe changed at will to accommodate the system to particular conditions.It is also to be understood that in arranging the several elements ofthe control valve means and of the automatic water softening system inthe single plane of a sheet of drawing the positional relationships ofcertain of the elements were necessarily distorted. The functionalrelationships among the several elements, however, remain the same.

Referring now to FIGURE 7 of the drawings, the control valve of thisinvention is shown schematically, mounted on the top of an elongated andupright tank 221 adapted to contain a supply or bed 222 of a watersoftening ion exchange material, such as zeolite, to a level at aboutonehalf to three-fourths of the tanks volumetric capacity to leave afreebroad area 223 at the top of the tank. Tank 221 is desirably formedof noncorrosive reinforced synthetic resinous material and is preferablyprovided with a rounded bottom.

The tank 221 is provided with a central tubular conduit 224 whose upperend is fitted into the projecting collar 155 on the bottom of thecontrol valve means and is held in place by a resilient 0-ring in theannular groove l56. Tube 224 is likewise preferably formed from anoncorrosive synthetic resinous material. The lower end of tube 224terminates in a bell 2225 supported by feet just off the surface of thebottom of the tank 221.. A fine screen 225 stretched across the bottomof the inverted bell 2 2.5 pred vents the ion exchange material in thetank from being drawn into the central vertical tube.

The control valve means is connected into a water distribution systemwith the hard water inlet connected to a source of hard water and withthe soft Water outlet 158 connected on the discharge side of thedistribution system. the softening cycle, the pressures upon diaphragmsin diaphragm valves 161?. and 177 are such that the diaphragms assumethe positions shown in broken lines in *F URE 7. Diaphragm valve 162 isopened and diavalve 177 is closed. During the softening cycle waterenters through inlet 157 to chamber l59. Plow through diaphragm valve177 is prevented because the greater pressure on the top of thediaphragm in that valve maintains the valve closed.

ater supply is maintained in line 227 to mainare upon the top of theresilient diaphragm in metering valve ll Any flow of water from line 227,revented by solenoid actuated valves 121V, 122V, and 123V, which remainclosed during the Water softening cycle. Because the pressure exerted bythe hard water supply main on the lower side of the diaphragm indiaphragm valve 162 is greater than the pressure on the upper side ofthe diaphragm that valve remains open. Hard er may thus flow throughvalve 1-62 to chamber 168 and into the top of the water softening tank221. The d water is forced down through a bed of mineral 222 he tank 221and in the course of its passage becomes softened by ion exchange, as iswell understood in the art. The resulting soft water enters the invertedbell at the bottom of the tank and is forced upwardly through tube 224to the chamber 186 at the bottom of the control valve.

Outward flow from chamber 1% through channel 215 is prevented by virtueof check valve 218 and the fact that diaphragm valve 217 is maintainedclosed by spring pressure and by the water pressure of the tank againstthe plunger to hold it closed. The soft water being under pressure, may,however, lift check valve 184- and enter chamber 183. No soft water mayflow through diaphragm valve 177 because that valve is closed. It isclosed by virtue of the superior pressure applied from the top of thewater softening tank through channel 11% and ducts 1 92 and 193, to thecap of the diaphragm valve 1'77, supplemented by spring pressure. Nohard water may escape through channel 1% because of check valve 213 andthe fact that diaphragm valve 196 is maintained closed by springpressure and by the water pressure of the tank against the plunger.

Upon the opening of any tap or faucet connected in the soft waterdistribution system. soft water may flow out through the soft wateroutlet 15%. At the same time, soft water 'is permitted to flow throughport 226 through a line 228 to a metering valve 1%) in a predeterminedfixed proportion to the amount of soft water drawn through the softwater outlet. in the manner described in deta l in my aforesaidco-pending application, Serial No. 676,777. The soft water metered outby the metering valve flows under pressure through a line t lt} througha T-fittiu g 14? which is connected to the vacuum dashpot )6 of a clockcontrol unit of the type described in my ctr-pending application, SerialNo. 693.481, filed October 30, 1957. and thence through a line 15% to aT-fitting 229 (which. in turn, is connected to the throat of a venturitube 73-h), and thence through tubing 1% to a salt strainer device i 43at the bottom of a brine generating tank where it contacts stored saltto generate a brine solution for use in regeneration of the mineralwater softening bed.

The construction of the salt strainer device 143 is decribed in detailin my co-pending application, Serial No. 496,862, filed March 25, 1955,now Patent No. 2,902,155 issued Sept. 1, 1959 and a preferred form ofbrine generating vessel is described in my co-pending application,Serial No. 709,055, filed January 15, 1958, now Patent No. 2,985,514issued May 23, 1961. Thus, in the operation of the water softeningsystem to soften water, soft water is withdrawn from the distributionsystem for use as needed and this is furnished by passage of hard waterthrough the system and out in the manner described. Simultaneously withthe normal consumption of soft water a predetermined fixed smallproportion of the soft water is by-passed to the brine generating vesselfor preparation of a brine solution for use in revitalizing the mineralbed when necessary.

Regeneration may be carried out when determined to be necessaryaccording to the volume of soft water consumed as reflected by the levelof brine present in the brine generating vessel, as described in detailin my aforesaid copending application, Serial No. 693,481.Alternatively, in some installations, as, for example, where soft waterconsumption is fairly uniform, regeneration may be carried out atpredetermined fixed intervals, such as every day, or every other day, orevery third day or the like. In any event, regeneration preferably iscarried out during periods of minimum soft water consumption, such as inthe extreme early morning hours, as, for example, 3 am.

The regeneration cycle is initiated by action of the control clock 40operating a switch to energize a solenoid controlling valve 121V. Whenthis happens, the pressure of the hard water supply main is exertedthrough the hard water inlet 157 upon chamber 159 and through port 16dand line 227 upon the valve 121V. Since this valve is now open, theWater at main pressure is permitted to fiow through the valve fordistribution as follows.

When valve 121V is opened, the pressure of the hard water supply line isexerted through line 231 upon one side of the two-way ball check valveelement 173 and upon the upper side of the resilient diaphragm 0f thediaphragm valve 162. This pressure, plus auxiliary spring pressure,forces the diaphragm against the valve seat in the solid line positionshown in FIGURE 7 to close valve 162. Pressure upon the ball 173prevents outward flow from the opposite side of the channel of thetwo-way check valve.

When valve 121V is opened, the pressure of the hard water supply line isalso exerted through line 232 upon the upper pressure chamber anddiaphragm of diaphragm drain valve 1%. One of the entry ports 206 or 207to the pressure chamber is plugged. The main pressure in the upperpressure chamber of diaphragm drain valve 196 is sufficient to overcomethe pressure or the coil spring in that diaphragm valve and open thatvalve to chamber 195 so that water may then flow from chamber 195 andout through one of the ports 202 or 203 below the diaphragm to a drainor sewer. A constant flow control device 233 is inserted between thevalve 121V and line 234- to venturi tube 239 (or, more precisely,between lines 231 and 232 and line 234, as shown in FIGURE 7) in orderto reduce the volume of the stream of water permitted to flow to theventuri tube.

Thus, with the first phase of the regeneration cycle initiated andsolenoid controlled valve 121V open, the pressure of the hard watersupply main is applied against the diaphragm of diaphragm valve 162 tomaintain that valve closed, with the assistance of spring pressure. Hardwater from chamber 159 is prevented from flowing to the top of the watersoftening tank relieving the top of the water softening tank from thesupply main pressure and also thereby relieving the top of the diaphragmof diaphragm valve 177 from that pressure. Accordingly, if any of thesoft water taps are opened during the period of regeneration, hard watermay now flow from the chamber 159 through the open diaphragm valve 177to the chamber 133. Check valve 184 prevents flow of this hard waterinto chamber 186 and tube 224. The hard water may, however, flow outthrough the soft water outlet 158 and in this manner, hard water isby-passed during the regeneration cycle. If any water is drawn from thesoft water taps during regeneration, a predetermined small o proportionof this water will flow through port 220 to be metered by metering valve10 into the brine generating vessel. This flow, however, will benegligible since normally no water will be drawn from the waterdistribution system during the regeneration cycle.

After initiation of the regeneration cycle the water flow released byopening of valve 121V maintains pressure upon the diaphragms ofdiaphragm valve 162 and diaphragm drain valve 1% in the mannerdescribed. The reduced flow through the flow control device 233 and line23% to the venturi tube 23% passes through a line .135 and through port219 to the control valve means lifting check valve 213 and passingthrough channel 215 to chamber 136. Diaphragm drain valve 217 remainsclosed, during this first phase of the regeneration cycle. As the waterfrom line 234 flows through the restricted throat of the venturi tube23ft it creates a reduced pressure within the throat which draws thebrine from the bottom of the tank 125 through the salt strainer unit 143and up through the tubing M6 and through the venturi tube for passagethrough line 235 and past check valve 218 into chamber and channel 215to chamber 136 at the bottom of the control valve means and at the topof tube 224 in the water softening tank.

Chamber iii? in the control valve means is at the pressure of the hardwater supply main. This insures that check valve 184 remains in place.The brine solution is thus forced down through tubing 224 to the bottomof the bed 222 of mineral water softening material and is distributed onthe bottom of the tank and forced upwardly through the mineral bed inion exchanging relationship. The brine solution rises through themineral bed to the freehoard 223 of the tank pus-hing the fresh water inthe freeboard of the tank ahead of it and out through channel 194 tochamber 195. Since the pressure upon the diaphragm in diaphragm drainvalve 1% now holds that valve open, the water forced from the watersoftening tank passes through the drain valve to a drain or sewer. Flowfrom chamber 195 is otherwise prevented by check valve 213.

After all of the brine in the brine generating tank has been withdrawnthrough the tube 146, the float valving element seats in the resilientvalve seat of the salt strainer unit 143 and creates a suction withintubing 146 which, in turn, transmits itself through line 15d and fitting149 to the vacuum dashpot 96 on the control clock. The vacuum exertedupon the dashpot 96 of the control clock introduces a time delay ofsufficient length to permit substantially all of the brine solution topass through the mineral bed to the freeboard of the tank 22?.

At the expiration of this delay period the clock control actuatesmicroswitches which deenergize the solenoid controlling valve 121V andenergize the solenoid controlling valve 122V. V hen this occurs,pressure is relieved upon diaphragm drain valve 1% causing that valve toclose. At the same time, pressure is relieved upon one side of thetwo-way ball check valving element 173 and would relieve pressure uponthe diaphragm in diaphragm valve 162 except that with solenoidcontrolled valve 122V now opened, the pressure of the hard water supplyline is asserted through valve 122V and line 236 upon the opposite sideof the ball 173 to maintain the pressure upon diaphragm valve 162. Thepressure of the hard water supply main is also asserted through valve122V and line 237 on the top of the diaphragm of diaphragm drain valve217. At the same time, water from line 237 passes under pressure throughport 214 (lifting check valve 213) and passes through channel 194 intothe top of the water softening tank 221.

This inflow of fresh water to the top of the water softening tank forcesthe brine left in the freeboard of the tank back down through themineral bed in the op posite direction and up through the central tube224 so that the brine solution passes through the mineral bed twice,once in each direction. This dual upflow and downflow contact of thebrine with the mineral water softening 9 material thus provides doublethe contact time between the brine and mineral facilitating and insuringcomplete revitalization of the mineral.

The brine solution forced upward through the central tube 224 intochamber 1% passes through channel 215 to chamber 216. Outflow fromchamber 215 through port 219 is prevented by check valve 216. However,since diaphragm drain valve 217 is now pressurized, that drain valve isopen and the brine solution passes through that valve and through thelower bowl of drain valve 1% to the drain or sewer. The flow of freshwater through solenoid actuated valve 122V is continued for a timeperiod predetermined by the setting of the control clock sufficient toinsure removal of all of the brine from the mineral bed and tothoroughly rinse the mineral with fresh water.

At the end of this second phase of the regeneration cycle, the clockcontrol actuates microswitches to deenergize the solenoid controllingvalve 122V and to energize the solenoids controlling valves 121V and123V. When this occurs, diaphragm drain valve 217 is again closed,diaphragm drain valve 1% is again opened and diaphragm valve 162 remainspressurized, but from line 231, instead of line 236, because of theshift in position of the two way ball check 173. Fresh water is injectedfrom valve 121V into port 219 and through tube 224 to the bottom of themineral bed, in the manner heretofore described for the introduction ofthe brine, but because of the relatively low volume of this flow, it issupplemented by a further flow through valve 123V and line 238 to port219. This larger volume supplemental flow flushes and rinses the mineralbed in its upfiow passage to remove any traces of brine or othercontaminants which may remain after the previous downflow rinsing.

This third phase of the regeneration cycle is allowed to continue for atime suificient to insure complete washing of the mineral bed. At theend of this period, the control device deenergizes all of the solenoidsso that valves 121V and 123V are then closed and the system is returnedto its normal water softening function. This means that diaphragm valve162 is depressurized, diaphragm valve 177 is pressurized, and diaphragmvalves 196 and 217 are both depressurized, but maintained closed byspring action. With the system returned to its normal condition, thenext water softening cycle is initiated.

By simple modification of its structure, the control valve means of thisinvention may be utilized in other water softening systems. One exampleof such a system which is somewhat simpler than that described in detailwith reference to FIGURE 7 is one having a two phase regeneration cyclein which the second passage of the brine solution in contact with themineral bed is dispensed with. This introduces a number ofsimplifications into the system. As an example, the second diaphragmdrain valve 217 may be eliminated and the threaded opening in the top ofchamber 216 may simply be fitted with a solid plug. At the same time,check valve 213 is no longer necessary and port 214 may be plugged. Thediaphragm valve 162 may simply be pressurized by the line 231 alone sothat the two-way check valve in the diaphragm valve 162 may beeliminated. Solenoid controlled valve 122V is no longer necessary.

Since the second flow of the brine solution in contact with the mineralbed has been eliminated, there is no need for the time delay ininitiating the second stage of the regeneration cycle and the vacuumdashpot 96 on the control clock along with the switches controlled bythe dashpot are no longer necessary. It will be apparent that otherarrangements may be made whereby the number and sequence of phases inthe regeneration cycle may be varied at will, along with the directionof flows during each of the phases. The control valve is versatile andadaptable to meet the operating demands of virtually any water softeningsystem.

In some water softening systems, such as semi-commercial or commercialinstallations, handling large volumes of water, it is desirable toutilize more than one tank of water softening mineral. in theseinstallations, the several water softening tanks are connected so thatthe mineral beds are regenerated in sequence, such as, for example, in atwo-tank system, the first tank may be regenerated on alternating nightswith the second tank. Since in such an installation the tank which isnot being regenerated is available to supply fresh soft water during theregeneration cycle of the other tank, there is no need for a fresh waterbypass in the system. Accordingly, the control valve means, when used ina system employing more than one water softening tank, may be modifiedand simplified by the deletion of diaphragm 186, spring Li, ducts192-193, and the substitution of a hollow plug for the annular valveseat element 181. Such a simpler modified control valve means may thenbe utilized to regulate the desired number of phases of the regenerationcycle and the sequence of their operation as described above.

It will be noted that the upper pressure chambers of each of thediaphragm drain valves E96 and 217 are provided with two entry ports.Likewise, the lower bowls of these diaphragm valves are provided withtwo ports. In many applications, such as, for example, the systemillustrated in FIGURE 7, only one of these ports may be used, in whichevent the other port is simply plugged. As shown in FIGURE 7, the draindischarge from diaphragm valve 217 passes through the lower bowl ofdiaphragm valve 196 on its way to the drain. This is a matter ofconvenience and drain valve 217 could, if desired, be connected directlyto a drain.

It is apparent that many modifications and variations of this inventionas hereinbefore set forth may be made without departing from the spiritand scope thereof. The specific embodiments described are given by wayof example only and the invention is limited only by the terms of theappended claims.

I claim:

1. A multi-port control valve mans comprising a valve body, a firstinlet port to said valve body and a first outlet port from said valvebody, said first ports being in communication through a first connectingchamber, a second inlet port to said valve body and a second outlet portfrom said valve body, said second ports being in communication through asecond connecting chamber, a pressure controlled diaphragm valvepositioned in said first chamber between said first inlet port and firstoutlet port, a one-way check valve positioned in said second chamberbetween said second inlet port and second outlet port to permit fiowonly in the direction toward said outlet port, a third inlet port andchannel in communication with said second inlet port, a one-way checkvalve positioned in said third port and channel to permit inflow onlythrough said third port and channel, a drain port from said controlvalve means, a third outlet port and channel in communication with saiddrain port, a second pressure controlled diaphragm drain valvepositioned between said third outlet port and channel and said drainport, means for pressurizing said diaphragm valves, and a further outletport from said valve body, said further outlet port being positionedbetween said second outlet port and the one-way check valve between saidsecond inlet port and said second outlet port.

2. A control valve means according to claim 1 further characterized inthat said means for pressurizing said diaphragm valves includes anauxiliary outlet port from said valve body, said auxiliary outlet portbeing positioned between said first inlet port and said pressurecontrolled diaphragm valve between said first inlet port and firstoutlet port, and inlet port to the diaphragm pressure chamber formingpart of each of said diaphragm valves.

3. A control valve means according to claim It further characterized inthat said first inlet port and second outlet port are in communicationthrough an interconnecting 1 l chamber and a further pressure controlleddiaphragm valve is positioned in said chamber between said first inletport and second outlet port.

4. A control valve means according to claim 2 further characterized inthat said inlet port to the diaphragm pressure chamber of said firstpressure controlled diaphragm Valve includes a two-way check valve, theopposite sides of said check valve being in communication with saidauxiliary outlet port.

5. A control valve means according to claim 1 further characterized inthat said check valves each comprise a circular disc, a resilient O-ringdisposed in an annular groove around the periphery of said disc, and apilot stem comprised of a pair of flat slotted members fitted togetherin said slots and secured to depend from said disc.

6. An automatic water softening system comprising means for connectionto a source of hard water and means for connection to a soft waterdistribution system, a water softening tank in communication with saidhard water and soft water connecting means through a control valve meansto receive and soften said hard water and discharge soft water fordistribution, a brine tank in communication with said water softeningtank through said control valve means for generating and storing brinefor regeneration of water softening mineral adapted to be contained insaid water softening tank, said control valve means being connected tosaid water softener tank, said control valve means comprising a valvebody having a hard water inlet port and a soft water outlet port, a hardwater outlet port in communication with said hard water inlet port andsaid water softener tank, a soft water inlet port in communication withsaid water softener tank and said soft water outlet port, a pressurecontrolled diaphragm valve between the hard water inlet port and hardwater outlet port, a one-way check valve between the soft water inletport and soft water outlet port to permit flow of soft water only in thedirection from the inlet port to the outlet port, a brine and freshwater inlet port and channel in communication with said soft water inletport and said brine tank, a one-way check valve in said brine and freshwater inlet port and channel to permit inflow only through said port andchannel, a drain port from said control valve means, a brine and freshrinse water discharge port and channel from said water softener tank tosaid drain port, a pressure controlled diaphragm drain valve in saidbrine and rinse water discharge port and channel to control discharge tosaid drain port, means for pressurizing said diaphragm valves, and anauxiliary soft water outlet port from said control valve means, saidauxiliary outlet port being positioned between said first mentioned softwater outlet port and the one-way check valve which is between the softwater inlet port and said first mentioned soft water outlet port, saidauxiliary soft water outlet port being in communication with said brinetank.

7. An automatic water softening system according to claim 6 furthercharacterized in that said control valve means is provided with afurther pressure controlled diaphragm valve between the hard water inletport and soft water outlet port to permit bypass of hard water duringregeneration of the system.

8. An automatic water softening system according to claim 6 furthercharacterized in that said means for pressurizing the diaphragm valvesof said control valve means includes an auxiliary hard water outlet portfrom said control valve means, said auxiliary hard water outlet beingpositioned between said first mentioned hard water inlet port and thepressure controlled diaphragm 12 valve which is between the hard waterinlet port and said first mentioned hard Water outlet port, and anauxiliary hard water inlet port to the diaphragm pressure chamberforming part of each of said diaphragm valves.

9. An automatic water softening system according to claim 6 furthercharacterized by the provision of a further fresh water inlet port insaid control valve means in communication with said brine and rinsewater discharge port and channel from said water softener tank and aone-way check valve in said further inlet port to permit inflow only tosaid discharge port and channel, and the provision of a further pressurecontrolled diaphragm drain valve in said control valve means in saidbrine and fresh water inlet port and channel, said drain portcommunicating with one chamber of said second pressure controlleddiaphragm drain valve.

10. An automatic Water softening system according to claim 8 furthercharacterized in that the auxiliary hard water inlet port to thediaphragm pressure chamber of the first mentioned pressure controlleddiaphragm valve between the hard water inlet port and hard water outletport of the control valve means includes a two-way check valve, theopposite sides of said two-way check valve being in communication withsaid auxiliary hard water outlet port.

11. An automatic water softening system according to claim 6 furthercharacterized in that said one-way check valves of said control valvemeans each comprise a circular disc, a resilient C-ring disposed in anannular groove around the periphery of said disc, and a pilot stemcomprised of a pair of flat slotted members fitted together in saidslots and secured to depend from said disc.

12. A multi-port control valve means comprising a valve body, a firstinlet port to said valve body and a first outlet port from said valvebody, said first ports being in communication through a first connectingchamber, a second inlet port to said valve body and a second outlet portfrom said valve body, said second ports being in communication through asecond connecting chamber, a pressure controlled diaphragm valvepositioned in said first chamber between said first inlet port and firstoutlet port, a one-way check valve positioned in said second chamberbetween said second inlet port and second outlet port to permit flowonly in the direction toward said outlet port, a third inlet port andchannel in communication with said second inlet port, a one-way checkvalve positioned in said third port and channel to permit inflow onlythrough said third port and channel, a drain port from said controlvalve means, a third outlet port and channel in communication with saiddrain port, a second pressure controlled diaphragm drain valvepositioned between said third outlet port and channel and said drainport, a fourth inlet port in communication with said third outlet portand channel, a one-way check valve in said fourth inlet port to permitinflow only to said third port and channel, a further pressurecontrolled diaphragm drain valve in said third inlet port and channel,said drain port communicating with one chamber of said further diaphragmdrain valve, and means for pressurizing said diaphragm valves.

References Qited in the file of this patent UNITED STATES PATENTS1,839,428 Waugh Jan. 5, 1932 2,265,225 Clark Dec. 9, 1941 2,352,629Griswold July 4, 1944 2,596,915 Pick May 13, 1952 2,677,390 Davis et alMay 4, 1954 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PatentNo., 3 O66 ,8O1 December 4 1962 Stanley AB Lundeen It is herebycertified that error appears in the above numbered patent requiringcorrection and that the said Letters Patent should read as correctedbelow.

Column Ti line 47 for or read M of column 1O line 39 for "mans" readmeans Signed and sealed this 4th day of June 1963a (SEAL) Attest:

DAVID L. LADD Attesting Ufiicer

